Panel

ABSTRACT

A panel formed from sheet material and suitable for roofing and other cladding type applications is described. The panel has opposite longitudinal edges and incorporates a plurality of longitudinally extending formations. The formations are generally of common shape but have at least one portion which is not of constant size across the panel. The panel in at least one form is formed from sheet steel and may be galvanized and/or have other outer protective coatings or finishes.

FIELD OF THE INVENTION

The present invention relates generally to panels made from sheet material such a sheet metal strip. The invention has been developed especially, but not exclusively, as infill panels for use in fences and is herein described in that context. The invention, however, may be used in other applications, such as wall and roof cladding, and is therefore not limited to fencing.

BACKGROUND OF THE INVENTION

Typically fences include fence posts made from timber or metal which are adapted to support barrier panels. Typically, each barrier panel comprises upper and lower rigid rails extending between the posts and infill elements extending from rail to rail. The infill elements may be impervious rigid sheet, a roll formed profile sheet, a rigid sheet of expanded metal, a plurality of spaced apart pickets, a sheet of woven wire mesh, or other substantially planar obstruction to the passage of people or animals between the posts. In many applications, particularly for domestic and commercial use, the fencing can be quite prominent and as such there is a continuing demand for fencing which is visually appealing which is relatively inexpensive to manufacture.

SUMMARY OF THE INVENTION

In one aspect of the present invention there is provided a cladding panel formed from sheet material having opposite longitudinal edges and being profiled to incorporate a plurality of longitudinally extending formations, the formations being of generally common shape but having at least one portion not of constant size across the panel.

The formations may be shaped as corrugations, upstanding elements such as ribs or pleats or the like and may incorporate pans or troughs that separate the upstanding elements. In this form, a cross-sectional profile of the panel may display a regular wave form with crests and troughs displaced from a notional centre plane of the sheet material. The wave form may be smoothly curved throughout or it may comprise straight portions meeting at relatively abrupt angles, or a combination of both these possibilities.

In one form, the formation that is repeated across the sheet may be of relatively simple shape such as a single corrugation cycle or a rib and pan combination. Alternatively, the formation may be a more complex shape that including multiple ribs (that may be of different size relative to one another) separated by a pan or by a combination of a rib, pleat, or corrugation or the like.

In one or more embodiments, the panel is profiled so as to give an appearance which is substantially uniform as the shape of the formation repeats across the panel. However, the variation of the size of at least one portion of respective of the formations introduces a more “natural” feel to the panel to make it more aesthetically pleasing, particularly in applications such as fencing or the like.

In one form, the size of the at least one portion of the formation increases along a first part of the panel width and decreases along a second part of the panel.

In one form, the panel includes at least three different sizes of the at least one portion of the formation across the panel.

In a particularly preferred form, the formation includes a gradually sloped surface and an abruptly sloped surface, with the surfaces being mutually inclined. As this formation repeats across the panel, a saw tooth profile is produced with a plurality of crests and troughs.

In one form, the length of the gradually sloped surface of the formations is not constant across the panel.

In one form, the length of the abruptly sloped surface of the formations is constant across the panel.

In one form, the gradually sloped surface includes at least one discontinuity in that surface.

In a particular form, where the repeated formations form a plurality of crests and troughs across the panel, the spacing of the crests from a notional centre plane of the panel is constant across the panel.

In one form of this arrangement, the spacing of the troughs from a notional centre plane of the panel is constant across the panel.

In one form, the panel is formed from a single sheet of material such that the repeated formations are formed in the single sheet.

In another form, the panel is formed from a plurality of panel members which are arranged side by side relative to one another with the longitudinal edges of adjacent panels being in overlapping relationship. In this latter arrangement, the individual panel members may include one formation or a plurality of formations which are identical both in shape and size. However, the formations in different panel members include the at least one portion having a size that varies across the panel members. With this arrangement, the panel members are combined to form the panel in a manner such that the panel has the characteristic repeated formations with variations being introduced in the size of the formations by the combining of the individual panel members.

In another aspect of the invention there is provided a cladding panel having a profile of repeated crests and troughs across the width of the panel, the profile being non-constant and having three or more different spacings between adjacent crests across the panel width.

In another aspect of the invention there is provided a fence incorporating a panel according to any form described above. In one embodiment, the panel is used as a barrier panel between posts of the fence. In that application, the panel can be used as an infill element which may be installed between upper and lower rigid rails that extend between the fence posts.

While one or more forms of panels embodied by the invention find particular application in the construction of fences and other barriers, the invention is not limited thereto and panels in accordance with the invention can be used in a variety of other applications such as roofing and the cladding of metal building frames and other structures, including in the construction of warehouses and sheds.

Hence in another aspect of the invention there is provided a roof incorporating a panel according to any form described above.

In still another aspect of the invention there is provided a wall or barrier incorporating a panel according to any form described above.

In another aspect of the invention there is provided an apparatus for fabricating a cladding panel, the apparatus comprising forming rolls for modifying the shape of sheet material passing through the nip of one or more sets of the rolls, the forming rolls being collectively adapted to shape the sheet material to form a panel having opposite longitudinal edges and being profiled to incorporate a plurality of longitudinally extending formations, the formations being of generally common shape but having at least one portion which is not of constant size across the panel.

Panels embodied by the invention provide a versatile building material and offer an attractive alternative to consumers.

Any discussion of documents, acts, materials, devices, articles or the like which has been included in this specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed in Australia or elsewhere before the priority date of this application.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers, integers or steps.

It is convenient to hereinafter describe embodiments of the invention with reference to the accompanying drawings. It will be understood however that the particularity of the drawings and the related description is not to be taken as limiting the preceding broad description of the invention.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

FIG. 1 is a perspective view of a panel embodied by the invention;

FIG. 2 is a cross-section of the panel of FIG. 1;

FIG. 3 is a schematic view of a fence including infill elements formed from the panel of FIG. 1;

FIG. 4 is a schematic view of a variation of the fence of FIG. 3; and

FIG. 5 is a cross-section of a further panel embodied by the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Turning firstly to FIGS. 1 and 2, a panel 10 is illustrated that is formed from sheet material, typically a sheet metal strip, for example a strip of steel coated with a protected coating of an alloy of aluminium and zinc which may have a decorative paint finish. The panel 10 has opposite major surfaces 11 and 12 that extend between longitudinal edges 13 and 14.

The panel 10 is profiled (typically by passing the sheet metal strip through a roll former) to include a plurality of formations 15 that extend in the longitudinal direction of the panel 10 between the longitudinal edges 13 and 14. The formations 15 are of generally common shape but include subtle variation(s) which will be described in more detail below.

To distinguish between the individual formations 15 of the panel 10, the formations are referenced in superscript with like components of those formations similarly designated. For convenience when referring to the formations in general, the reference will be made without use of such superscript.

The formations 15 each include a gradually sloped surface 16 and abruptly sloped surface 17 that are mutually inclined. As the formation 15 repeats along the panel, it provides a saw tooth profile with a series of repeated crests and troughs (18 and 19 respectively) with the crests being formed at the junction between the gradually sloped surface 16 and the abruptly sloped surface 17 of the individual formations (15 ^(i) . . . 15 ^(vii)), whereas the troughs 19 are formed at the junction between the formations.

The gradually sloped surfaces 16 define respective major portions of the formations 15 and include a plurality of discontinuities 20 to break up that portion of the formations 15. In the particular embodiment of the panel shown, the discontinuities delineate minor formations 23 within the major portion of each formation 15 and provide junctions from which the slope of the surface 16 alters. The minor formations are also of generally sawtooth shape such that the gradually sloped surface 16 itself is defined by alternating gently sloped and abruptly sloped sections, which complement the overall sawtooth appearance of the panel. As best shown in FIG. 2, the size of respective of the minor saw tooth formations differ such that the widths of the gently sloped sections of the surface 16 also vary across the formation. As will be understood, the sizes of the minor sawtooth formations can differ from one formation 15 the next and a panel 10 can be provided in which no two formations 15 of the panel are the same.

Nevertheless, as can be seen in FIGS. 1 and 2, the individual formations (15 ^(i) . . . 15 ^(vii)) are of a generally common shape. The distance of the crests 18 from a notional Centre Line (CL) of the panel is essentially constant across the panel 10. Similarly the distance of the troughs 19 from the Centre Line CL is also essentially constant. Furthermore, the length and orientation of the abruptly sloped surface 17 is constant across each instance of that surface (17 ^(i) . . . 17 ^(vii)). However a variation is introduced in the length of the gradually sloped surfaces (16 ^(i) . . . 16 ^(vii)) to break up the strict symmetry of the panel and give it a more “natural” feel.

In the illustrated embodiment, the width of the gradually sloped surface sequentially increases across the formations 15 ^(i) through to a maximum at 15 ^(iv). In the illustrated form, the increase in width is by increments of approximately 10%. Thereafter, the width of the portion 16 of the formations 15 ^(iv) through to 15 ^(vii) decreases by a similar increment across those formations.

The panel 10 is arranged to be laid side by side with the longitudinal edges 13 and 14 of adjacent panels being in overlapping relationship. To facilitate installation each of the longitudinal edges 13 and 14 includes an edge profile 21 and 22 respectively. When laid in this formation the continuous surface formed by the interconnected panels has a pattern wherein the width of the respective gradually sloped surfaces 16 incrementally increases and then subsequently decreases across portions of that surface in a pattern which is akin to being sinusoidal.

The panel 10 is ideally suited to be used in fencing. As illustrated in FIG. 3, a fence 100 is disclosed which uses a plurality of the panels (10 ^(i) . . . 10 ^(n)) which form the infill element of the fence. In the illustrated form, the fence 100 includes spaced apart fence posts 101 which are interconnected by rigid top and bottom rails 102, 103. The panels 10 ^(i), 10 ^(ii) and 10 ^(iii) are disposed between the rails 102 and 103 to form the infill elements of the fence 100. Because of the characteristic profiling of the infill element 104 formed by the individual panels 10, it displays a regular structure with the repeated formations 15. However, these formations have a more natural feel in view of the subtle variations which are introduced by the variations in the width of the abruptly sloped surfaces 16 of the individual formations which in the illustrated form provide a sinusoidal effect across the infill elements 104.

A variation on the design is illustrated in FIG. 4 where the infill element 104 is made from a series of narrower panel members (50 ^(i) . . . 50 ^(n)). In the embodiment of FIG. 4 each of the panel members 50 include a repeated formation with each formation 15 being identical in both shape and size. However, the formations in different panel members include at least one portion that varies in size between the panel members. With this arrangement, the gradual variation in the width of that portion of the formation can still be achieved to some extent by the combination of the panels which are used to form the infill element 104. Specifically, in the embodiment shown in FIG. 4, the length of that one portion increases from panel 50 ^(i) to 50 ^(iv) and then decreases from panel 50 ^(iv) through to 50 ^(vii). By continuing this process the sinusoidal variation is again maintained in a somewhat similar manner as that appearing in the infill element 104 of FIG. 3.

The cross-sectional profile of a further panel 60 embodied by the invention is shown in FIG. 5. As with panel 10 shown in FIG. 1 and FIG. 2, this panel has an essentially sawtooth shaped profile with formations 15 ^((i−v)) being of a generally common shape, and each formation having an abruptly sloped surface 17 ^((i−v)) and a gradually sloped surface 16 ^((i−v)) defining a major portion of the formation. Similarly, the size of the major portion of the formations 15 increases across the panel to a maximum width in formation 15 ^(iii) then decreases to a minimum width in formation 15 ^(v).

As also shown, formations 15 ^(i) and 15 ^(ii) of panel 60 incorporate discontinuities forming rippled sections 61 within the major portions of those formations. In contrast, the major portion of formation 151 ^(iii) incorporates discontinuities 20 delineating minor sawtooth, pan, and trough formations designated by the numerals 61 to 63 across the gradually sloped surface 16 of that formation. Formation 15 ^(iii) also differs from formations 15 ^(iv) and 15 ^(v) which incorporate minor pan 62 and trough 63 formations but no minor sawtooth formations 61. The overall result is a panel in which formations 15 differ from one another yet provide the panel with overall consistency in appearance.

Accordingly, a panel is disclosed which provides subtle variations in the profiling to soften the appearance of the panel when used to form surface elements. Such arrangements are particularly suitable for fencing and the like where a more “natural” appearance is desirable. While panels embodied by the invention have particular application in fencing and the construction of external barriers, one or more embodiments of the panel can also be used for roofing applications including the cladding of awnings and skillet type roofs, and for cladding walls of building structures such as warehouses, sheds, dwellings and the like. For such roofing or cladding applications, the panels can be secured to underlying support members of metal structural frames by any suitable fasteners conventionally used for this purpose.

Although panels embodied by the invention with generally sawtooth shaped formations 15 have been described above, panels with differently shaped formations 15 can be provided. For instance the formations can be essentially corrugated in form wherein respective corrugations are of different widths and incorporate discontinuities 20 which break up the curvature of the corrugations. Similarly, or as well, the curvature of respective corrugations can differ. Thus, the invention is not limited to the particular shape of the formations 15 of the panels and various shapes of the formations are possible as described herein. As further examples, the formations 15 may comprise upstanding ribs or pan sections at least a portion of which differ in size from one to the next across at least a first portion of the panel. Similarly, the formations 15 can incorporate a plurality of discontinuities 20 whereby differently shaped minor formations can be defined in respective of the major portions of the formations. The number of discontinuities in different ones of the formations 15 of a panel can also vary such that the major portion of adjacent formations 15 of the panel differ not only in size from one to the next but also in appearance.

Hence, it will be understood by persons skilled in the art that numerous variations and/or modifications may be made to the invention without departing from the spirit or scope of the invention as broadly described. For example, the skilled addressee would be able to readily modify the control system yet still obtain clamping of the blade of the saw. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. 

1. A cladding panel formed from sheet material having opposite longitudinal edges and being profiled to incorporate a plurality of longitudinally extending formations, the formations being of generally common shape but having at least one portion which is not of constant size across the panel.
 2. A panel according to claim 1, wherein in one direction across the panel, the size of the at least one formation increases along a first part of the panel, and decreases along a second part of the panel.
 3. A panel according to claim 1, wherein there are at least three different sizes of the at least one portion across the panel.
 4. A panel according to claim 1, wherein the at least one portion has at least a component of its length that extends in the plane of the panel.
 5. A panel according to claim 1, wherein the formation has a surface defining a major portion of the formation, the surface incorporating at least one discontinuity in that surface.
 6. A panel according to claim 5 wherein the at least one discontinuity delineates respective minor formations within the major portion.
 7. A panel according to claim 6 wherein respective of the minor formations differ from one another.
 8. A panel according to claim 1, wherein the formation includes a gradually sloped surface and an abruptly sloped surface, the surfaces being mutually inclined so that the panel has a saw tooth profile.
 9. A panel according to claim 8, wherein the width of the gradually sloped surface of the formations is not constant across the panel.
 10. A panel according to claim 8, wherein the width of the abruptly sloped surface of the formations is constant across the panel.
 11. A panel according to claim 8, wherein respective of the gradually sloped surfaces include at least one discontinuity in that surface.
 12. A panel according to claim 11 wherein the gradually sloped surface defines a major portion of the formation and the discontinuities delineate respective minor formations within the major portion.
 13. A panel according to claim 12 wherein respective of the minor formations differ from one another.
 14. A panel according to claim 13 wherein the minor formations differ in size.
 15. A panel according to claim 12, wherein respective of the minor formations are individually selected from the group consisting of sawtooth shaped formations, pans, and troughs.
 16. A panel according to claim 11, wherein respective of the discontinuities provide a junction from which the slope of the gradually sloping surface across the formation alters.
 17. A panel according to claim 1, wherein the formations produce a plurality of crests and troughs across the panel.
 18. A panel according to claim 17, wherein the spacing of the crests from a notional centre plane of the panel is constant across the panel.
 19. A panel according to claim 17, wherein the spacing of the troughs from a notional centre plane of the panel is constant across the panel.
 20. A panel according to claim 1, wherein in one direction across the panel width, the spacings between adjacent crests increases along a first portion of the panel width and decreases along a second portion of the panel width.
 21. A panel according to claim 1, wherein the panel is formed from a plurality of panel members, each panel member having opposite longitudinal edges and being profiled to include at least one of the longitudinal extending formations, the panel members being arranged in side by side relation with the longitudinal edges of adjacent panel members overlapping, wherein the formations of the panel members are of generally common shape but have at least one portion which is not of constant size across the panel.
 22. A panel having a profile of repeated crests and troughs across the width of the panel, the profile being non-constant and having three or more different spacings between adjacent crests across the panel width.
 23. A panel according to claim 1 being fabricated from sheet steel.
 24. A fence comprising infill elements disposed between spaced apart fence posts, wherein the infill elements include a plurality of panels as defined in claim
 1. 25. A roof structure incorporating a panel formed from sheet material having opposite longitudinal edges and being profiled to incorporate a plurality of longitudinally extending formations, the formations being of generally common shape but having at least one portion which is not of constant size across the panel.
 26. A wall or barrier incorporating a panel formed from sheet material having opposite longitudinal edges and being profiled to incorporate a plurality of longitudinally extending formations, the formations being of generally common shape but having at least one portion which is not of constant size across the panel.
 27. An apparatus for fabricating a cladding panel, the apparatus comprising forming rolls for modifying the shape of sheet material passing through the nip of one or more sets of the rolls, the forming rolls being collectively adapted to shape the sheet material to form a panel having opposite longitudinal edges and being profiled to incorporate a plurality of longitudinally extending formations, the formations being of generally common shape but having at least one portion which is not of constant size across the panel.
 28. A panel according to claim 21 being fabricated from sheet steel. 